Cookie Blowoff Using The Full-Flow Air Knife

A machine manufacturer was working with a food company who was looking to design a blowoff station for their cookie making process. During the production cycle, the cookie dough is put into a former that pushes the dough through round dyes that forms several rows of cookies across a conveyor. As the cookies travel down the conveyor, they are topped with ground peanut bits and sent through a flash freezing process. It was after this process, the company was looking to install the blowoff station to remove any excess peanut bits but were concerned if the air velocity was too high, they may remove too much of the ground peanuts or possibly blow the cookies themselves off of the conveyor. Another area of concern was the amount of space available to install the station was limited, so they were needing something “compact” so they could design the machine to take the least amount of real estate as possible.

The machine designer was somewhat familiar with our Air Knives, but was unsure which design would best fit the customer’s needs so they decided to reach out for assistance. After discussing the particulars, I recommended our 36″ Stainless Steel Full-Flow Air Knife Kit. Of the 3 designs of Air Knife we offer, the Super, Standard and Full-Flow, the Full-Flow Air Knife produces the lowest outlet velocities, it is also our smallest profile offering at only 1.25″ x 1″  for stainless steel construction. The Full-Flow Air Knife provides a laminar flow of air the entire length of the knife and uses a 30:1 amplification rate (entrained air to compressed air) for efficient compressed air usage. By incorporating the pressure regulator included in the kit, they would be able to easily control the exiting air velocity to effectively remove the excess peanut bits without ejecting the cookies from the line.

Full-Flow

The Full-Flow Air Knife is the ideal choice where mounting space is limited. Lengths available up to 36″ in aluminum or stainless steel construction.

For assistance in selecting the best Air Knife to fit your needs or for additional support with another application or EXAIR product, give me a call at 800-903-9247, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Custom, Flanged Air Amplifier Solves a Fume Evacuation Problem

We blog about this topic quite a bit, and almost every section of our catalog has a page set aside just for special / custom product configurations that have been created by request from many of our customers.

This is the latest and greatest special that I have seen roll through the production area here at EXAIR.   This is a special 4″ 303 Stainless Steel Adjustable Air Amplifier with a 4″ Tri-Clamp flange on the discharge side and a 6″ Tri-Clamp flange on the suction side of the amplifier.

 

This had been an ongoing project with the customer that started with them testing a stock Adjustable Air Amplifier in the application to ensure that the performance would meet their needs.  The application was to boost a low flowing fume exhaust that was causing slow downs in their production line.  Fans and other traditional methods would require maintenance and would wear out.  The stock Adj. Air Amplifiers exceeded their performance needs but did not easily mount into their duct work because they used all standard size tri-clamp fitting in the ducting, so the next step was to see if we could manufacture a Special Adjustable Air Amplifier just for their needs.  The dimensions of the existing Adjustable Air Amplifier came close enough we were able to easily create a Flanged Adjsutable Air Amplifier that would clamp straight into their existing duct work, exceed their performance expectations, help their process, and be ready to ship within a very reasonable lead time.

Like we have said before, if a stock, cataloged, product doesn’t fit your application exactly, contact us and let us find a way to customize and fit the need.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Stainless Steel Adjustable Air Amplifiers Replace Blower in Exhaust Hood Application

Vent hood

EXAIR Stainless Steel Adjustable Air Amplifiers model 6034

 

I was working with our Indonesian distributor the other day on an interesting application in the sugar refining industry.

The application was in a sugar refining plant. As the sugar cane is cooked down, the resulting gas vapor is pulled up through a vent hood and exhausted outside the building. The customer was using a 16” diameter blower to create the needed draft to draw the vapors. The problem is that the vapors are corrosive and sticky when cold. The effect is that the blower blade becomes caked with deposits which, in turn corrode the blade and it must either be cleaned and/or replaced at frequent and regular intervals.

The customer wanted to get away from having to deal with the blower issue if they can, so they turned to our distributor for ideas on how to solve the problem using EXAIR equipment. Turns out that a cluster of (3) model 6034 4” Adjustable Air Amplifiers operating at 5 BARG input pressure are able to generate the necessary flow to replace the blower in this system.

The keys to success in the application were the fact that the Adjustable Air Amplifiers are constructed of Stainless Steel to resist the corrosive effects of the gas vapor. Also, there isn’t any deposits on the blade that need to be dealt with. While cleaning of the Air Amplifiers is recommended in this application, the maintenance interval was able to be much longer between cleanings.

In many industrial applications, blower driven or electric motor driven equipment is usually preferred in an effort to save energy. This was a good example of a case where the quality of having no moving parts was able to offset other maintenance costs that made use of a blower actually more expensive for the user.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

 

Full-Flow Air Knife Assists With Flour Recovery

I took a call from a customer who was looking for a way to recover residual corn flour on their chain and paddle, drag conveyor. As the paddles moved down the line, they would start accumulating flour which was leading to uneven batch runs and waste. After reviewing the application with the customer, they determined they were only needing to blow off the width of the paddles, so I recommend using our 18” stainless steel Full-Flow Air Knife.

The Full-Flow Air Knife provides a 30:1 amplification rate (entrained air to compressed air), to produce a high velocity curtain of air that travels the entire length of the knife. With a small profile of only 1” H x 1.25” W, the unit is the ideal choice where mounting space is limited. It is available in a 303SS material which was suitable for this wash-down application.

Full-Flow

The Full Flow Air Knife is available in aluminum or stainless steel construction, up to 36″ stocked lengths.

 

Due to the concern regarding dust, I recommended operating the unit at a gentle 20 PSIG, lowering the velocity to 3,000 FPM and reducing the air consumption to only 1.1 SCFM per inch. A simple pressure regulator is capable of adjusting the volume and velocity of output airflow in order to “fine tune” our knives per application. This would allow for the needed blowoff, as well as reduce the potential of the unwanted dust.

If you have a similar application or would like to discuss your process, please don’t hesitate to give us a call at 1-800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

How To Choose An Air Knife

The EXAIR Super Air Knife has a prominent place near the front of our catalog, and THIRTEEN pages of photos, application details, performance data & specifications. It’s the most efficient and quietest product of its kind on the market, and our most diverse product offering in terms of size range, operational adjustability, materials of construction, and accessories available. For almost any general industrial air blow off application, the EXAIR Super Air Knife is the superior choice in terms of air usage, sound level, and capability.

EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.

EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.

As tireless champions of the causes of reducing air consumption and noise, we’re always going to promote these benefits of the Super Air Knife. Still, a caller asked me the other day, “Well, why do you still make the others?”…meaning, of course, our Standard and Full Flow Air Knives. Why, indeed:

*Given the same air supply pressure, the Standard Air Knife generates the highest force of our three styles. The amount of force applied isn’t always a prime consideration…if you think about one of the more “textbook” applications for an Air Knife, it doesn’t take a great amount of force to blow off dust and light debris from a conveyor belt…certainly this is a case where efficiency factors in: the lower air consumption of a Super Air Knife can pay for the cost difference between it and a Standard Air Knife in as little as three months of operation.

The Standard Air Knife has the highest force, for when it's needed.

The Standard Air Knife has the highest force, for when it’s needed.

Of course, if you’re blowing stubborn debris out of tight spaces, like gummy, greasy dirt that’s accumulating in the recesses of a finned tube heat exchanger, that extra force can make all the difference. No; the Standard Air Knife isn’t as efficient or quiet as the Super Air Knife, but it’s still a far cry better than a drilled pipe.

*While the Super Air Knife is pretty compact – you only need a few square inches of profile area to successfully mount it – the Full Flow Air Knife is even smaller, requiring not much more than one square inch of profile for mounting. With ports on the rear face (instead of the ends & bottom for the Super Air Knife,) they can fit in very tight quarters.

Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.

Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.

The Full Flow Air Knife is also the lightest weight for a given length. A 36” Aluminum Super Air Knife, for instance, weighs about 8lbs. The 36” Aluminum Full Flow Air Knife weighs less than 4lbs. Most of the time, 8lbs is a very manageable amount of mass to support, but there are situations where every ounce matters, and if yours is one of them, you’re looking at the Full Flow Air Knife all the way.

*The biggest (in the most literal sense) factor in Air Knife selection is, well…size. We make the Standard Air Knives in lengths to 48”, and the Full Flow Air Knives come as long as 36”. The Super Air Knives, however, are stocked in lengths from 3” to 108”, and can be coupled together for as long of an uninterrupted, steady, laminar air flow as you need.

At the end of the day, a majority of blow off applications can be handled just fine with any of our Air Knives. If you’d like to discuss your application and see which one is best for you, give us a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
Find us on the Web
Follow me on Twitter
Like us on Facebook

The Versatile Line Vac

Of all the tools that I own, my cordless drill has to be just about my favorite. I’m remodeling a bathroom in my house right now, and last night I was setting the new toilet flange onto the new tile floor. I had to drill some holes for this through the new tile. I’d never done this before, and was definitely feeling some heartburn about it. Especially after finding out just how fragile and brittle ceramic tile is…I cracked two pieces, just trying to cut a hole for the heat & AC vent register. Luckily, that was BEFORE I mortared & grouted it in, so it wasn’t a big deal…they’re about a buck a piece, and I got five extra anyway.

I know how to do this...but I have no idea how to fix this.

I know how to do this                                                 but I have no idea how to fix this.

THIS one, though, was fully installed, and, despite all the internet videos I found & watched on how to install a tile floor, I haven’t yet had the need to find one that shows me how to replace a broken tile. And I don’t really want to, so I went slowly and carefully with the drill, using the special glass & tile bit that I bought. On my first hole, when I got the bit through the tile itself, I changed to a different (smaller) bit to pilot the screw hole through the subfloor. Then, I put a Phillip’s head bit in to drive the screw. It occurred to me that I was performing these three related but separate tasks, with the same tool…I just thought that was very cool.

Over the course of the last couple of days, I’ve talked to three different callers, with three different Line Vac applications:

HDLV

 

*One wants to use a Model 150200 2” Heavy Duty Line Vac to convey cement. They’re currently hauling the bags, by hand, up to a hopper, where they cut them open and dump them in.

 

Heavy Duty Threaded Line Vac

*One needs to move small springs, one at a time, from a hopper to an automated assembly turret machine.  The springs are 5/8″ in diameter, and they’ll be fed through a length of PVC pipe.  Our Model 151100 1″ NPT Heavy Duty Threaded Line Vac will be easily installed in the pipe line using standard threaded fittings, and the springs will pass through the 0.75″ throat nicely.

 

sslv

 

*One has a auger-type chip conveyor that removes machining debris from a lathe, and it’s broken…again. They needed a Model 6066 3” Stainless Steel Line Vac, in a hurry, to use until they get their chip conveyor fixed. In fact, if it works, they may not fix the chip conveyor.

 

With a wide range of sizes and materials of construction, we've got your solution.  Call us.

With a wide range of sizes and materials of construction, we’ve got your solution. Call us.

So, kind of like my cordless drill, our Line Vac Air Operated Conveyors have a variety of uses, right out of the box. If you have an application that you think a Line Vac may be able to solve, give me a call.  By the way, if you order one before the end of October, 2014we’ll give you a FREE 2″ Flat Super Air Nozzle.  Really.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

EXAIR Receives Plant Engineering Product of the Year Awards

Every year EXAIR strives to meet our customer needs with new products. On a day to day basis we communicate with customers who voice problems for which we might or might not have a solution. When we can’t help a customer, we see that as an opportunity to grow our business and meet those customers needs. Over the last year we have released over 250 products to fill our customer’s requests. We submitted 4 of those products to Plant Engineering for voting by their readers for Product of the Year.

IMG_3902

The 2013 Product of the Year Awards – One silver and three gold!

All (4) products were recognized by Plant Engineering and their readers this year.

The awards received, the products and the categories were:

Gold Award – 1 Inch Flat Super Air Nozzle – Compressed Air

1126pr_300wide

Gold Award – Dual 316 Stainless Steel Cabinet Coolers – Electrical Controls

NEMA 4X Dual Steel

Gold Award – No Drip External Mix Atomizing Nozzles – Fluid Handling

nodrip_AF

Silver Award – Heavy Duty HEPA Vac – Environmental Health

HD HEPA

Over the next month, I will talk about each product and detail their features, benefits and applications. If you need help on any application, feel free to contact us.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

 

%d bloggers like this: